US7569039B2 - Disposable pull-on garment - Google Patents

Abstract

A disposable pull-on garment includes an absorbent main body and a ring-like elastic belt forming a waist opening and two leg openings. The absorbent main body has longitudinal side edges and transverse end edges. The elastic belt includes a front belt and a back belt each having a transverse waist border and a transverse abdomen border. In the back belt, a waist border elastic material is disposed adjacent to the waist border between the waist border and the end edge of the absorbent main body, a side elastic material is disposed adjacent to the abdomen border, and a waist anchoring elastic material is disposed between them. A leg opening angle formed by the abdomen border and each of the longitudinal side edges of the absorbent main body is greater when the disposable pull-on garment is in a contracted configuration than when the disposable pull-on garment is in an uncontracted configuration.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This Application claims the benefit of U.S. Provisional Application No. 60/523,262, filed Nov. 19, 2003.

FIELD OF THE INVENTION

The present invention relates to disposable pull-on garments which are donned by inserting the wearer's legs into the leg openings and sliding the garment up into position about the lower torso.

BACKGROUND OF THE INVENTION

Many pull-on diapers use elastic elements secured in an elastically contractible condition in the waist and leg openings. Typically, in order to insure full elastic fit about the leg and the waist such as is provided with durable undergarments, the leg openings and waist opening are encircled with elasticized bands of rubber or other materials positioned along the curve of the opening. Examples of such pull-on diapers are disclosed inEP 1 184 012 A1 published on Mar. 6, 2002. The pull-on diaper disclosed therein comprises an absorbent body and an exterior member covering the absorbent body and forming a contour of the diaper. The absorbent body is substantially rectangular and comprises a liquid-permeable topsheet, a liquid-impermeable backsheet and an absorbent core interposed therebetween. The leg and waist elastic members are provided at the body-surrounding portion in the exterior member to form an elasticized leg opening and an elasticized waist opening. The longitudinal sides of the exterior member are trimmed to form leg openings. While trimming the longitudinal sides of the exterior member allows the desired shape of curved leg opening to be formed, it requires an additional process for trimming and wastes raw materials.

Another example of pull-on diapers is disclosed in Japanese Laid-open Publication No. H4-144558 published on May 19, 1992. The pull-on diaper disclosed therein comprises an absorbent main body and an elastic belt joined to the front region and the back region of the absorbent main body. The upper end of the elastic belt defines a waist opening. The lower end of the elastic belt and the longitudinal side of the absorbent main body jointly define a leg opening. The elastic belt extends in the transverse direction of the diaper and the absorbent main body extends in the longitudinal direction. Therefore, the lower end of the elastic belt and the longitudinal side of the absorbent main body intersect at a right angle to define the leg opening. Such a configuration having an angular shape gives a poor aesthetic appearance impression to the user when the user takes a fresh diaper out of the bag, as compared with a pull-on diaper having a desired shape of curved leg opening.

Based on the foregoing, there is a need for a disposable pull-on garment having an aesthetic appearance while providing a cost advantage in forming a pull-on diaper. None of the existing disposable pull-on garment provides all of the advantages and benefits of the present invention.

SUMMARY OF THE INVENTION

The present invention is directed to a disposable pull-on garment having a waist opening and leg openings and extending in a longitudinal direction and a transverse direction. The pull-on garment comprises an absorbent main body and a ring-like elastic belt. The absorbent main body comprises a liquid pervious topsheet, a liquid impervious backsheet and an absorbent core disposed therebetween. The absorbent main body has longitudinal side edges, transverse end edges, a front waist panel, a back waist panel and a crotch panel. The front waist panel and the back waist panel are not joined directly. The ring-like elastic belt is surrounded by a transverse waist border and a transverse abdomen border. The ring-like elastic belt has a central panel and side panels. The central panel is joined to the front waist panel and the back waist panel of the absorbent main body to form one waist opening and two leg openings. The ring-like elastic belt is not disposed in the crotch panel of the absorbent main body. The ring-like elastic belt comprises a belt layer and a belt elastic material joined to the belt layer. The belt elastic material is provided with the belt layer such that the leg opening angle formed by the transverse abdomen border of the side panel and the longitudinal side edge of the absorbent main body is greater when the disposable pull-on garment is in a contracted configuration than when the disposable pull-on garment is in an uncontracted configuration.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which is regarded as forming the present invention, it is believed that the invention will be better understood from the following description which is taken in conjunction with the accompanying drawings and which like designations are used to designate substantially identical elements, and in which:

FIG. 1 is a perspective view of the disposable pull-on garment of the present invention in a typical in-use configuration;

FIG. 2 is a top plan view of the pull-on garment in its flat uncontracted condition showing the inner surface;

FIG. 3 is a cross-sectional view ofFIG. 2 taken along the line III-III;

FIG. 4 is a cross-sectional view ofFIG. 2 taken along the line IV-IV;

FIG. 5 is a cross-sectional view ofFIG. 2 taken along the line V-V;

FIG. 6 is a schematic perspective view of the outer cover layer in a typical in-use configuration without showing other elements of the pull-on garment;

FIG. 7 is a schematic top plan view of the combination of the ring-like elastic belt and the outer cover layer without showing an absorbent man body;

FIG. 8 is a schematic cross-sectional view ofFIG. 7 taken along the longitudinal centerline L;

FIG. 9 is a cross-sectional view showing a typical in-use configuration of the portion shown inFIG. 3;

FIG. 10 is a schematic top plan view of the pull-on garment in its flat uncontracted condition showing the inner surface;

FIG. 11 is a schematic front view of the pull-on garment in its contracted condition for comparison;

FIG. 12 is a schematic front view of the pull-on garment ofFIG. 10 in its contracted condition;

FIG. 13 is a schematic front view of the pull-on garment to explain a positional relationship of various elements of the garment in its contracted condition;

FIG. 14 is a schematic front view of an alternative embodiment of the pull-on garment to explain a positional relationship of various elements of the garment in its contracted condition;

FIG. 15 is a schematic top plan view of an alternative embodiment of the pull-on garment in its flat uncontracted condition showing the inner surface;

FIG. 16 is a schematic front view of the pull-on garment ofFIG. 15 in its contracted condition;

FIG. 17 is a schematic top plan view of the pull-on garment in its flat uncontracted condition showing the outer surface;

FIG. 18 is a schematic side view of the pull-on garment in its use condition; and

FIG. 19 is a schematic side view of a conventional pull-on garment in its use condition.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, the term “pull-on garment” refers to articles of wear which have a defined waist opening and a pair of leg openings and which are pulled onto the body of the wearer by inserting the legs into the leg openings and pulling the article up over the waist. The term “disposable” is used herein to describe garments which are not intended to be laundered or otherwise restored or reused as a garment (i.e., they are intended to be discarded after a single use and, preferably, to be recycled, composted or otherwise disposed of in an environmentally compatible manner). The pull-on garment is also preferably “absorbent” to absorb and contain the various exudates discharged from the body. A preferred embodiment of the pull-on garment of the present invention is the disposable absorbent pull-on garment, pull-ondiaper20, shown inFIG. 1. As used herein, the term “pull-on diaper” refers to pull-on garments generally worn by infants and other incontinent individuals to absorb and contain urine and feces. It should be understood, however, that the present invention is also applicable to other pull-on garments such as training pants, incontinent briefs, feminine hygiene garments or panties, and the like.

FIG. 1 is a perspective view of the pull-ondiaper20 of the present invention. The pull-ondiaper20 has anouter surface22, aninner surface24 opposed to theouter surface22, afront region26, aback region28, acrotch region30, andseams32 which join thefront region26 and theback region28 to formleg openings34 and a waist opening36. Thediaper20 comprises an absorbent main body38 (hereinafter may be referred to as “main body”) to cover the crotch region of the wearer, a ring-like elastic belt40 (hereinafter may be referred to as “elastic belt” or “belt”) extending transversely about thewaist opening36, and anouter cover layer42 to cover themain body38. Theelastic belt40 defines thewaist opening36, and theelastic belt40 and themain body38 jointly defines theleg opening34. The pull-ondiaper20 also has apatch sheet44 printed with a graphic46 thereon which may be disposed in thefront region26 and/or theback region28.

The absorbentmain body38 absorbs and contains body exudates disposed on themain body38. In the embodiment shown inFIG. 2, themain body38 has a generally rectangular shape having a longitudinal centerline L, longitudinal side edges48 and transverse end edges50. Themain body38 also has afront waist panel52 positioned in thefront waist region26 of thediaper20, aback waist panel54 positioned in theback waist region28, and acrotch panel56 in thecrotch region30.

Themain body38 comprises a liquidpervious topsheet58, a liquidimpervious backsheet60 and anabsorbent core62 disposed therebetween. Themain body38 may additionally comprise abarrier leg cuff64 disposed along thelongitudinal side edge48. Thebarrier leg cuff64 provides improved containment of liquids and other body exudates in thecrotch region30. Thebarrier leg cuff64 shown inFIG. 3 comprises a single layer of material which is folded into two layers. Thebarrier leg cuff64 extends from thelongitudinal side edge48 toward the longitudinal centerline L and then is folded along thefolding line66 back toward thelongitudinal side edge48. Thebarrier leg cuff64 has a barrier cuffelastic material72 at thedistal edge68. Theproximal edge70 of thebarrier leg cuff64 is joined to thebacksheet60 adjacent thelongitudinal side edge48. The portion of thebarrier leg cuff64 along thefolding line66 and thedistal edge68 are free from attachment to any portion of themain body38 in thecrotch panel56 such that thebarrier leg cuff64 stands up toward the wearer's body when thediaper20 is used. Thetransverse end74 of thebarrier leg cuff64 is joined to thetopsheet58 adjacent thefolding line66 by an attachment means76 which may be any known means such as an adhesive and is joined to thebarrier leg cuff64 itself along thedistal edge68 by an attachment means78 which may be any known means such as an adhesive as shown inFIG. 4.

The liquidpervious topsheet58 is preferably positioned adjacent the body-facing surface of theabsorbent core62 and may be joined thereto and/or to thebacksheet60 by any attachment means known in the art. The liquidimpervious backsheet60 is generally that portion of thediaper20 positioned adjacent the garment-facing surface of theabsorbent core62 and prevents the exudates absorbed and contained therein from soiling articles that may contact thediaper20. The absorbent core is positioned between thetopsheet58 and thebacksheet60 and absorbs and retains liquids such as urine and other certain body exudates. Thetopsheet58, thebacksheet60 and the absorbent core may be manufactured any known materials. Suitable topsheet materials may include porous foams; reticulated foams; apertured plastic films; or woven or nonwoven webs of natural fibers (e.g., wood or cotton fibers), synthetic fibers (e.g., polyester or polypropylene fibers), or a combination of natural and synthetic fibers. Suitable backsheet materials may include breathable materials that permit vapors to escape from the diaper while still preventing exudates from passing through the backsheet. Suitable absorbent core materials may include creped cellulose wadding; meltblown polymers, including coform; chemically stiffened, modified or cross-linked cellulosic fibers; tissue, including tissue wraps and tissue laminates; absorbent foams; absorbent sponges; superabsorbent polymers; absorbent gelling materials; or any other known absorbent material or combinations of materials.

The ring-likeelastic belt40 extends transversely about the waist opening36 of thediaper20 and acts to dynamically create fitment forces and to distribute the forces dynamically generated during wear. Theelastic belt40 comprises afront belt84 and a back belt86 (hereinafter may be collectively referred to as “front andback belt84,86) which are joined at theseam32 to form a pull-on diaper having a waist opening and two leg openings. Each of thefront belt84 and theback belt86 has acentral panel80 andside panels82 positioned transversely outward from thecentral panel80. Each of thefront belt84 and theback belt86 also has atransverse waist border88 and a transverseabdomen border90. Thetransverse waist border88 defines thewaist opening36. Thecentral panel80 of thefront belt84 may partly or entirely overlap with thefront waist panel52 of themain body38. Thecentral panel80 of theback belt86 may partly or entirely overlap with theback waist panel54 of themain body38. However, thecentral panel80 of the front andback belt84,86 does not extend into thecrotch panel56 of themain body38 and is not disposed in thecrotch panel56. In the embodiment shown inFIG. 2, thecentral panel80 of thefront belt84 and theback belt86 partly overlaps with thefront waist panel52 and theback waist panel54, respectively.

The ring-likeelastic belt40 comprises abelt layer91 including anouter layer92. Thebelt layer91 further comprises aninner layer94. A beltelastic material96 is interposed between theouter layer92 and theinner layer94. Thefront belt84 and theback belt86 may comprise the same materials and/or may have the same structure. Alternatively, thefront belt84 and theback belt86 may comprise different materials and/or may have different structures. As shown in the embodiment ofFIG. 2, thefront belt84 and theback belt86 generally have the same structure. Referring toFIG. 5, theinner layer94 has atransverse waist edge104 and a transverseabdomen edge106. Theouter layer92 has atransverse waist end108 and a transverseabdomen end110. Theinner layer94 is almost coextensive with the contour of the front andback belt84,86. Alternatively, theinner layer94 may be smaller than the size of the front andback belt84,86. Theouter layer92 of thebelt layer91 is longer than the size of theinner layer94 in the longitudinal direction and anend flap112 of theouter layer92 is folded to cover thetransverse waist edge104 of theinner layer94 at thewaist opening36 and to form atransverse waist end108 of theouter layer92. Theinner layer94 of thebelt layer91 may also have an end flap which may be folded together with theend flap112 of theouter layer92. The end flap of theinner layer94 may be longer or shorter than or equal to the end flap of theouter layer92. Alternatively, theend flap112 may be eliminated such that theouter layer92 terminates at thewaist opening36 to form atransverse waist end108. In the embodiment shown inFIGS. 2 and 5, thetransverse waist end108 and the transverseabdomen end110 of theouter layer92 correspond to thetransverse waist border88 and the transverseabdomen border90 of the front andback belt84,86, respectively. Theouter layer92 surrounded by thetransverse waist end108 and the transverseabdomen end110 defines the shape of the front andback belt84,86 in the embodiment shown inFIGS. 2 and 5.

The front andback belt84,86 may have any shape to provide a ring-like belt. In the embodiment shown inFIG. 2, the transverseabdomen border90 and thetransverse waist border88 extends transversely straight and in parallel to each other. Alternatively, the transverseabdomen border90 may be shaped such that the longitudinal length between thetransverse waist border88 and the transverseabdomen border90 in thecentral panel80 is longer or shorter than the longitudinal length between thetransverse waist border88 and the transverseabdomen border90 in theside panel82.

The front andback belt84,86 may comprise any known materials. Suitable material for the front andback belt84,86 can be manufactured from a wide range of materials such as plastic films; apertured plastic films; woven or nonwoven webs of natural materials (e.g., wood or cotton fibers), synthetic fibers (e.g., polyolefins, polyamides, polyester, polyethylene, or polypropylene fibers), or a combination of natural and/or synthetic fibers; or coated woven or nonwoven webs. Preferably the belt comprises a nonwoven web of synthetic fibers. The belt may comprise a stretchable nonwoven. More preferably, the belt comprises an inner hydrophobic, non-stretchable nonwoven material and an outer hydrophobic, non-stretchable nonwoven material.

The beltelastic material96 comprises a waistelastic material98 and a sideelastic material100. The waistelastic material98 may comprise one or more of elastic elements such as strands or panels extending in the transverse direction. The sideelastic material100 also may comprise one or more of elastic elements such as strands or panels extending in the transverse direction. The waistelastic material98 is continuously disposed along thetransverse waist border88 of the front andback belt84,86. The sideelastic material100 is preferably disposed in theside panel82 of the front andback belt84,86. In the embodiment shown inFIG. 2, the waistelastic material98 and the sideelastic material100 comprise a plurality of elastic strands which are disposed at a constant interval in the longitudinal direction. Alternatively, the waistelastic material98 and the sideelastic material100 may be disposed at a different interval in the longitudinal direction. No elastic material may be provided in a portion of thecentral panel80 of the front andback belt84,86 which overlaps with theabsorbent core62, preferably with the front andback waist panel52,54 of themain body38. Alternatively, no elastic material may be provided in the entirety of thecentral panel80. However, an elastic material may be provided in thecentral panel80 if it is necessary. The beltelastic material96 is interposed between theouter layer92 and theinner layer94 and joined therebetween in an uncontracted condition of the beltelastic material96 such that the front andback belt84,86 provides elasticity when thediaper20 is used.

Theouter cover layer42 is disposed on theouter surface22 of thediaper20 and covers thecrotch panel56 of the absorbentmain body38. Theouter cover layer42 has a generally rectangular shape havinglongitudinal side portions114 and transverse end portions116 (refer toFIG. 5). Thelongitudinal side portion114 extends transversely outward beyond thelongitudinal side edge48 of themain body38. Thelongitudinal side portion114 is provided with a legelastic material118 to form an elastic leg cuff122 (refer toFIG. 3). The legelastic material118 is disposed so as to extend generally longitudinally along thelongitudinal side portion114. The legelastic material118 may be disposed at least in thecrotch region30 of thediaper20 and may not be disposed along the entirety of thelongitudinal side portion114. In order to form theelastic leg cuff122 in the embodiment, thelongitudinal side portion114 is folded to form asleeve120 to encase the legelastic material118. Thetransverse end portion116A of thelongitudinal side portion114 is folded toward the longitudinal centerline L of themain body38 and tacked down in the folded configuration by any known means such as adhesives, heat bonding, pressure bonding, ultrasonic bonding, etc. Thetransverse end portion116A is preferably folded inwardly so as to be adjacent the liquidimpervious backsheet60 of themain body38 and is joined onto itself by a bonding means119 to maintain its folded configuration (refer toFIGS. 4 and 6). Thetransverse end portion116A may be also joined to the liquidimpervious backsheet60 by a bonding means121. Thelongitudinal side portion114 in thecrotch region30 is free from attachment (refer toFIGS. 3 and 6) such that thelongitudinal side portion114 serves as theelastic leg cuff122 when thediaper20 is used. Alternatively, thetransverse end portion116A may be folded onto thelongitudinal side edge48 of themain body38. Alternatively, thetransverse end portion116A may be folded outwardly so as to be away from the liquidimpervious backsheet60.

Theouter cover layer42 comprises a material separate from the material of theinner layer94 and theouter layer92 constituting theelastic belt40. Theouter cover layer42 may comprise two of more layer of materials. Theouter cover layer42 may comprise any known materials and may comprise materials as used for the front andback belt84,86 as explained above. Preferably theouter cover layer42 comprises a single layer of nonwoven web of synthetic fibers. More preferably, theouter cover layer42 comprises a single layer of hydrophobic, non-stretchable nonwoven material.

Theouter cover layer42 covers thecrotch panel56 of the absorbentmain body38. Theouter cover layer42 may extend into and cover thefront waist panel52 and theback waist panel54 of themain body38. Theouter cover layer42 is directly joined to and covers the liquidimpervious backsheet42 of themain body38. In the configuration where thetransverse end portion116A of thelongitudinal side portion114 is folded inwardly so as to be adjacent the liquidimpervious backsheet60 of the main body and joined onto itself by the bonding means120, thecentral panel80 of the front andback belt84,86 is joined to thefront waist panel52 and theback waist panel54 of themain body38 through theouter cover layer42. Thus, theouter cover layer42 is sandwiched between the front andback belt84,86 and the liquidimpervious backsheet60 of themain body38. Thetransverse end portion116A is hidden underneath the front andback belt84,86. Thefront belt84 and theback belt86 are joined at theseam32 to form the ring-likeelastic belt40. However, thefront waist panel52 and theback waist panel54 are not directly joined along the longitudinal side edges48 but are only indirectly joined through the front andback belt84,86.

FIG. 7 shows a schematic top plan view of a combination of a ring-like elastic belt and an outer cover layer of the present invention without showing an absorbent main body.FIG. 8 is a schematic cross-sectional view ofFIG. 7 taken along the longitudinal centerline L. The front andback belt84,86 of the ring-likeelastic belt40 comprises two layers of nonwoven to hold the beltelastic materials96. However, the ring-likeelastic belt40 formed with two layers of nonwoven (inner layer94 and outer layer92) does not extend into thecrotch region30 of the diaper. Instead, theouter cover layer42 comprising a single layer of nonwoven is disposed in thecrotch region30. This structure is less costly, allows thecrotch region30 of the diaper to be less bulky and eliminates various drawbacks of conventional pull-on diaper. Theouter cover layer42 comprising a nonwoven material also provides a cloth-like appearance together with the ring-likeelastic belt40 comprising a nonwoven material. Theouter cover layer42 is formed with a separate material from the material of theinner layer94 and theouter layer92. Therefore, thelongitudinal side portion114 of theouter cover layer42 can be folded along the longitudinal direction to form theelastic leg cuff122 or thetransverse end portion116A along thelongitudinal side portion114 can be tacked down as explained above without being interfered by the front andback belt84,86. Such folding can be done before theouter cover layer42 and the front andback belt84,86 are joined to one another. Theelastic leg cuff122 formed by thelongitudinal side portion114 extends transversely outward beyond thelongitudinal side edge48 of the main body38 (not shown inFIGS. 7 and 8). Theelastic leg cuff122 stands up and covers thelongitudinal side edge48 to reduce leakage from themain body38 when thediaper20 is used (refer toFIG. 9). Further, thetransverse end portion116A which is inwardly folded and tacked down in its folded configuration ensures theelastic leg cuff122 to stand up securely in the crotch region30 (refer toFIG. 6 showing a schematic perspective view of theouter cover layer42 in a typical in-use configuration without showing other elements of diaper20).

FIG. 10 is a schematic top plan view of the pull-ondiaper20 in its flat uncontracted condition showing the inner surface. The pull-ondiaper20 comprises a combination of a transversely extending rectangular front andback belt84 and86, a longitudinally extending rectangularmain body38 and a longitudinally extending rectangularouter cover layer42. In the embodiment shown inFIG. 10, theouter cover layer42 extends transversely outward beyond thelongitudinal side edge48 of themain body38. The combination of theouter cover layer42 and the front andback belt84,86 defines thecounter edge21 of thediaper20. Constructing a pull-on garment with such a combination of generally rectangular shaped members is beneficial to make a costly effective garment which does not require trimming a material of garment. However, the combination of a generally rectangular members such as the front andback belt84,86 and theouter cover layer42 could provide an artificial appearance to thediaper20 because of the angular shape of the members. Specifically, in the embodiment shown inFIG. 10, the transverseabdomen border90 of the front andback belt84,86 extending transversely straight and thelongitudinal side portion114 of theouter cover layer42 extending longitudinally straight intersect each other to form aleg opening angle130 that is a right angle, which decreases a real garment-like appearance and increases an artificial appearance for a garment. Such a garment tends to maintain the angular appearance as shown inFIG. 11 even when the garment is contracted by the beltelastic material96. The angular appearance of the garment is primarily caused by the transverseabdomen border90 extending transversely straight and theleg opening angle130 being a right angle even after the garment is contracted. It is also caused by the angular appearance of the front andback belt84,86 having thetransverse waist border88 and the transverseabdomen border90, both extending transversely straight and the seams extending longitudinally straight even after the garment is contracted.

FIG. 12 shows a front view of the pull-ondiaper20 of the present invention in its contracted configuration. The transverseabdomen border90 of theside panel82 inclines with respect to the transverse direction such that theleg opening angle130 formed by the transverseabdomen border90 and thelongitudinal side portion114 is greater when thediaper20 is in a contracted configuration as shownFIG. 12 than when thediaper20 is in an uncontracted configuration as shown inFIG. 10. Theleg opening contour131 formed by the transverseabdomen border90 and thelongitudinal side portion114 of theouter cover layer42 in the front view of the contracteddiaper20 is similar to a curved leg opening contour. Therefore, such a configuration contributes to increase a real garment-like appearance of thediaper20 especially around the leg opening when the user takes a fresh garment out of the package. In addition, theseam32 is inclined with respect to the longitudinal direction and thetransverse waist border88 is curved when thediaper20 is contracted. These shape the front andback belt84,86 to increase a real garment-like appearance when thediaper20 is contracted. Theleg opening angle130 may be between 95 degree and 145 degree and preferably between 110 and 130 degree to increase a real garment-like appearance in a contracted condition of the garment. The difference of theleg opening angle130 between when the diaper is uncontracted and when the diaper is contracted may be between 10 degree and 50 degree and preferably between 20 degree and 40 degree.

FIG. 13 shows a schematic front view of the pull-ondiaper20 shown inFIG. 12 to explain the positional relationship of various elements of thediaper20. BecauseFIG. 12 is only schematically drawn, the number of the belt elastic material inFIG. 10 is different fromFIG. 1 or2.FIG. 13 shows other elements of thediaper20 such as the absorbentmain body38, the beltelastic material96 having the waistelastic material98 and the sideelastic material100, and the legelastic material118. Themain body38 extends generally in the longitudinal direction such that thelongitudinal side edge48 of themain body38 extends generally in the longitudinal direction in an uncontracted configuration (refer toFIG. 10). The bottom sideelastic material101 is disposed generally in parallel to the transverseabdomen border90 in an uncontracted configuration. The legelastic material118 extends generally in parallel to thelongitudinal side portion114 of theouter cover layer42 and/or thelongitudinal side edge48 of themain body38 in an uncontracted configuration. As explained above, the transverseabdomen border90 of theside panel82 inclines with respect to the transverse direction such that theleg opening angle130 formed by the transverseabdomen border90 and thelongitudinal side portion114 is greater when thediaper20 is in a contracted configuration than when thediaper20 is in an uncontracted configuration (refer toFIG. 12). The transverseabdomen border90 also forms theleg opening angle132 with the legelastic material118 and theleg opening angle134 with thelongitudinal side edge48 of themain body38. In a contracted configuration of thediaper20, the leg opening angle(s)132 and/or134 are (is) greater when thediaper20 is in a contracted configuration than when thediaper20 is in an uncontracted configuration. The bottom sideelastic material101 forms theleg opening angle136 with thelongitudinal side portion114 of theouter cover layer42, theleg opening angle138 with the legelastic material138, and theleg opening angle140 with thelongitudinal side edge48 of themain body38. In a contracted configuration of thediaper20, the leg opening angle(s)136,138 and/or140 are (is) greater when thediaper20 is in a contracted configuration than when thediaper20 is in an uncontracted configuration.

FIG. 14 shows an alternative embodiment of the pull-ondiaper20. The pull-ondiaper20 shown inFIG. 14 does not have anouter cover layer42. The legelastic material118 is directly joined to the absorbentmain body38 along thelongitudinal side edge48. In this embodiment, the transverseabdomen border90 forms theleg opening angle132 with the legelastic material118 and theleg opening angle134 with thelongitudinal side edge48 of themain body38. The bottom sideelastic material101 forms theleg opening angle138 with the legelastic material138 and theleg opening angle140 with thelongitudinal side edge48 of themain body38. Theleg opening angle134 may be between 95 degree and 145 degree and preferably between 110 and 130 degree to increase a real garment-like appearance in a contracted condition of the garment. The difference of theleg opening angle134 between when the diaper is uncontracted and when the diaper is contracted may be between 10 degree and 50 degree and preferably between 20 degree and 40 degree.

FIGS. 15 and 16 shows another alternative embodiment of the pull-ondiaper20. The front andback belt84,86 is shaped in the embodiment shown inFIGS. 15 and 16. More concretely, the transverseabdomen border90 of the front andback belt84,86 has a convex shape which protrudes towards the other side of the front andback belt84,86. Therefore, theleg opening angle130 formed by the transverseabdomen border90 and thelongitudinal side portion114 of theouter cover layer42 is greater than 90 degree in an uncontracted configuration of thediaper20. Theleg opening angle130 is greater when thediaper20 is contracted than when thediaper20 is uncontracted. It also contributes to increase a real garment-like appearance. Alternatively, the front andback belt84,86 may be shaped such that theleg opening angle130 is less than 90 degree in an uncontracted configuration of thediaper20 but is greater than 90 degree in a contracted configuration of thediaper20. The front andback belt84,86 may also have a different shape from one another.

The beltelastic material96 is provided with thebelt layer91 of the front andback belt84,86 such that the leg opening angle is greater when thediaper20 is in a contracted configuration than when thediaper20 is in an uncontracted configuration. More concretely, when the waistelastic material98 and the sideelastic material100 are joined to thebelt layer91, the waistelastic material98 and the sideelastic material100 are stretched to different stretched lengths. The waistelastic material98 is stretched greater than the sideelastic material100 when they are joined to thebelt layer91. When thediaper20 having the front andback belt84,86 thus formed is contracted by the returning force of the waistelastic material98 and the sideelastic material100, the transverse width of thetransverse waist border88 is shorter than the transverse width of the transverseabdomen border90 to shape the front andback belt84,86 as shown inFIG. 12.

The waistelastic material98 may be stretched to between 100% and 300%, preferably between 150% and 250% when being joined to thebelt layer91 to obtain a garment having an aesthetic appearance. The sideelastic material100 may be stretched to between 50% and 250%, preferably between 100% and 200% for the same purpose. Herein, the stretchability of, e.g., “100%” means that a material is stretched to twice as long as the unstretched material length. When the waistelastic material98 comprises a plurality of elastic materials, the stretched lengths of each elastic materials may be different. Likewise, when the waist sideelastic material100 comprises a plurality of elastic materials, the stretched lengths of each elastic materials may be different. It is preferable that the elastic material disposed adjacent to thetransverse waist border88 is stretched greater than the elastic material disposed adjacent to the transverseabdomen border90. While the sideelastic material100 may extend to cross the absorbentmain body38 and the sideelastic material100 on the left side panel and the right side panel may be connected, it is preferable that the sideelastic material100 is not disposed on the absorbentmain body38 so that the portion of thediaper20 where the absorbent core is present is not contracted. It also helps shaping the front andback belt84,86 as shown inFIG. 12 by not contracting the portion of thecentral panel80. Thetransverse width142 of thebelt layer91 in which the sideelastic material100 is joined (i.e., the transverse width of the side panel82) is between 50% and 80% of thetransverse width144 of thebelt layer91 in which the waistelastic material98 is joined (i.e., the transverse width of the transverse waist border88) in an uncontracted configuration of the disposable pall-ondiaper20.

FIG. 17 shows a schematic top plan view of the pull-ondiaper20 in its flat uncontracted condition showing the outer surface. As explained above, the beltelastic material96 comprises the waistelastic material98 and the sideelastic material100. The waistelastic material98 disposed in theback belt86 further comprises a waist borderelastic material146 and a waist anchoringelastic material148, each of which may comprise a plurality of elastic elements such as strands or panels. The waist borderelastic material146 is disposed along thetransverse waist border88 of theback belt86. The waist anchoring waistelastic material148 is disposed extending transversely between the waist borderelastic material146 and the sideelastic material100. The sideelastic material100 disposed in theback belt86 further comprises a side panelelastic material150 and a side legelastic material152. The side panelelastic material150 is disposed in the middle of theside panel82 of theback belt86. The side legelastic material152 is disposed along the transverseabdomen border90 of theback belt86. The waistelastic material98 and the sideelastic material100 disposed in thefront belt84 may have the same structure as those disposed in theback belt86.

The waist anchoringelastic material148 generates a greater stress against an applied extension force than the sideelastic material100 in theback belt86. The applied extension force is applied to an elastic material of the garment to stretch the elastic material for fitting the garment to the wearer. The waist anchoringelastic material148 preferably generates a greater stress against an applied extension force than the waist borderelastic material146 in theback belt86. The waist anchoringelastic material148 also preferably generates a greater stress against an applied extension force than the side legelastic material152 in theback belt86. Further the waist anchoringelastic material148 preferably generates a greater stress against an applied extension force than the side panelelastic material150 in theback belt86. The stress generated by the waist borderelastic material146, the side legelastic material152 and the side panelelastic material150 may be the same or may be different from each other. The waist anchoringelastic material148 generates a stress at 150% stretch of between 2 N and 6 N, preferably between 3 N and 5 N. The waist borderelastic material146 generates a stress at 150% stretch of between 0.2 N and 2.2 N, preferably between 0.4 N and 2 N. The sideelastic material100 generates a stress at 150% stretch of between 1 N and 5 N, preferably between 2 N and 4 N. The stress of the sideelastic material100 equals to the total stress adding the stress of the side legelastic material152 and the stress of the side panelelastic material150. The stress of eachelastic material146,148 and100 is determined by measuring the stress of each elastic element constituting theelastic material146,148 and100 and adding each stress of the elastic elements. A tensile tester suitable for use herein is available from Instron Corporation (100 Royall Street, Canton, Mass. 02021, U.S.A.) as Code No. Instron 5564. The gauge Length should be 20 mm and the crosshead speed should be 500 mm/min. Desired stress can be achieved by any known means such as changing the material elastic and changing the thickness of the elastic material.

Thediaper20 having the waist anchoringelastic material148 generating a greater stress against an applied extension force than the sideelastic material100 in theback belt86 improves a detachment problem between the ring-likeelastic belt40 and theouter cover layer42 covering the absorbentmain body38 and improves an aesthetic appearance of thediaper20 when it is worn on the wearer. The waist anchoringelastic material148 is fitted to theconcave back waist156 above the hip of the wearer as shown inFIG. 18 and generates the stress greater than the sideelastic material100 to anchor thediaper20 on the wearer. The leg sideelastic material152 of the sideelastic material100, however, generates the stress less than the waist anchoringelastic material148 and readily stretches to follow the downward force X generated by the legelastic material118 and the absorbent main body38 (not shown inFIG. 18) heavily loaded by urine or other body exudates. Therefore, the detachment problem can be improved around thejuncture154 between theouter cover layer42 covering the absorbentmain body38 and theelastic belt40 joined with the side legelastic material152. The waist anchoringelastic material148 also generates a greater stress against an applied extension force than the waist borderelastic material146 such that the waist anchoringelastic material148 generates an force anchoring thediaper20 to theconcave back waist156 of the wearer. Since the waist borderelastic material146 only generates a less stress than the waist anchoringelastic material148, the waist borderelastic material146 readily stretches to follow the movement of the wearer to surround the wearer's high back waist above theconcave back waist156. It improves an aesthetic appearance of thediaper20 when it is worn on the wearer. Thefront panel84 may have the same structure such that the waist anchoring elastic material may generate a greater stress against an applied extension force than the waist border elastic material, the side leg elastic material, and/or the side panel elastic material. In contrast,FIG. 19 shows a conventional garment having a waist elastic material generating a high stress to anchor the garment on the wearer's body. Since the waist elastic material generates a high stress, thetransverse waist border88 sags down to conform to the shape of the wearer'sconcave back waist156. It causes a bunching158 of thegarment20.

The waist borderelastic material146, the waist anchoringelastic material148 and the sideelastic material100 are stretched when they are joined to thebelt layer91 of theback belt86. It is preferable that the waist anchoringelastic material148 is stretched less than the waist borderelastic material146 and the sideelastic material100 when being joined to thebelt layer91. While the waist anchoringelastic material148 generates a high stress for anchoring, the waist anchoringelastic material148 being less stretched when being joined to thebelt layer91 suppresses giving an excessive force to the wearer's skin to avoid skin disorders. The waist borderelastic material146 is preferably stretched greater than the sideelastic material100 when they are joined to thebelt layer91. This increases a real garment-like appearance in a contracted condition of thediaper20 as explained above.

The waist anchoringelastic material148 may be disposed to overlap with a portion of the absorbentmain body38. In the embodiment shown inFIG. 17, the waist anchoringelastic material148 overlaps with themain body38 adjacent thetransverse end edge50. This allows to suppress giving an excessive force to the wearer's skin to avoid skin disorders.

Theouter layer92 of thebelt layer91 is folded along thetransverse waist border88 toward the liquidpervious topsheet58 of the absorbentmain body38 to form anend flap112 as explained above. Theend flap112 covers a portion of the absorbentmain body38 at theback region28 as shown inFIG. 2. Theend flap112 also overlaps with the waist anchoringelastic material148. Alternatively, theinner layer94 of thebelt layer91 may be folded along thetransverse waist border88 to form anend flap112. Since theend flap112 intervenes between the waist anchoringelastic material148 and the wearer's skin when thediaper20 is worn by the wearer, theend flap112 functions to suppress giving an excessive force to the wearer's skin to avoid skin disorders.

All documents cited in the Detailed Description of the Invention are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims (9)

1. A disposable pull-on garment comprising:

an absorbent main body comprising a liquid pervious topsheet, a liquid impervious backsheet and an absorbent core disposed therebetween, and having longitudinal side edges, transverse end edges, a front waist panel, a back waist panel and a crotch panel between the front waist panel and the back waist panel; and

a ring-like elastic belt joined to the backsheet in the front waist panel and the back waist panel of the absorbent main body to form one waist opening and two leg openings, the ring-like elastic belt not extending into the crotch panel of the absorbent main body,

wherein the ring-like elastic belt comprises a front belt and a back belt each having laterally opposing side panels, a central panel between the side panels, a transverse waist border, and a longitudinally opposing transverse abdomen border, the waist border being disposed longitudinally beyond the respective end edge of the absorbent main body,

each of the front belt and the back belt comprises a belt layer and a belt elastic material joined to the belt layer, the belt elastic material comprising a transverse waist elastic material disposed adjacent to the waist border and a transverse side elastic material disposed only in each of the side panels adjacent to the abdomen border laterally outboard of the respective waist panel of the absorbent main body and not overlapping the respective waist panel, the respective waist panel not being overlapped by any transverse elastic material between the side elastic material disposed in the side panels, the waist elastic material of the back belt comprising a transverse waist border elastic material disposed between the waist border of the back belt and the transverse end edge of the absorbent main body adjacent to the back belt, and

the belt elastic material is provided with the belt layer such that a leg opening angle formed by the transverse abdomen border and each of the longitudinal side edges of the absorbent main body is greater when the disposable pull-on garment is in a contracted configuration than when the disposable pull-on garment is in an uncontracted configuration.

2. The disposable pull-on garment ofclaim 1 wherein the pull-on garment comprises an outer cover layer, the outer cover layer comprises a material separate from the ring-like elastic belt, the outer cover layer has longitudinal side portions and transverse end portions, the outer cover layer covers the crotch panel of the absorbent main body, and each of the longitudinal side portions of the outer cover layer is provided with a leg elastic material to form an elastic leg cuff.

3. The disposable pull-on garment ofclaim 2 wherein each of the longitudinal side portions of the outer cover extends transversely beyond the respective longitudinal side edge of the absorbent main body.

4. The disposable pull-on garment ofclaim 3 wherein the belt elastic material is provided with the belt layer such that a leg opening angle formed by the transverse abdomen border and each of the longitudinal side portions of the outer cover layer is greater when the disposable pull-on garment is in the contracted configuration than when the disposable pull-on garment is in the uncontracted configuration.

5. The disposable pull-on garment ofclaim 2 wherein the belt elastic material is provided with the belt layer such that a leg opening angle formed by the side elastic material and the respective leg elastic material is greater when the disposable pull-on garment is in the contracted configuration than when the disposable pull-on garment is in the uncontracted configuration.

6. The disposable pull-on garment ofclaim 5 wherein the side elastic material is disposed to extend generally in the transverse direction and the leg elastic material is disposed to extend generally in the longitudinal direction when the disposable pull-on garment is in the uncontracted configuration.

7. The disposable pull-on garment ofclaim 1 wherein the waist elastic material and the side elastic material are stretched when being joined to the belt layer, the waist elastic material being stretched greater than the side elastic material.

8. The disposable pull-on garment ofclaim 7 wherein the waist elastic material is stretched to between 100% and 300% and the side elastic material is stretched to between 50% and 250%.

9. The disposable pull-on garment ofclaim 8 wherein the transverse width of the belt layer in which the side elastic material is joined is between 50% and 80% of the transverse width of the belt layer in which the waist elastic material is joined in the uncontracted configuration.

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